Carton Assembly

ABSTRACT

A carton assembly has a carton having an interior that has inner walls defining a tray portion and an insert disposed within the tray portion for retaining an article within the interior of the carton. Either the tray portion or the insert, or both, include a receiving structure for supporting the insert. The insert may have a substantially hollow beam structure. The hollow beam structure of the insert has an open end that is engaged by a tab or tabs extending from an inner wall or walls of the carton. A center panel extends between each tab and the bottom wall of the carton and engages the open end of the hollow beam.

CROSS-REFERENCE TO RELATED APPLICATIONS

This application claims the benefit of priority under 35 U.S.C. §119(e)of U.S. provisional application Ser. No. 60/747,126, filed on May 12,2006, which is hereby incorporated by reference in its entirety.

FIELD OF THE INVENTION

This invention relates to carton assemblies for holding items. Morespecifically, this invention relates to cartons and inserts wherein thecarton includes a pair of spaced apart double wall structures thatinclude a receiving structure for attaching an insert, and wherein theinsert includes a hollow beam structure configured to be attached to thedouble wall receiving structure. Further, the insert is configured toreceivably secure an item.

BACKGROUND OF THE INVENTION

Manufacturers and distributors often desire to distribute and sell itemsin packaging that is specifically adapted for the unique characteristicsof the articles. For example, sometimes the articles are fragile, easilymarred, impaired, or defaced, and therefore must be protected frompotentially damaging contact. In addition, articles may have aconfiguration that make it difficult to secure the article fromundesirable movement during transport, using conventional methods. Someexamples of articles that are fragile and/or easily marred, impaired, ordefaced, and that also may have a configuration that makes it difficultto secure include pens, syringes, vials, ampoules, medical devices,cosmetics, and electronic parts and assemblies.

When manufactures and distributors of products must use packaging tosell or distribute unique products, they typically desire to use themost desirable but cost effective packaging. However, specialtypackaging is typically more costly than standard packaging. Thus, it canbe appreciated that it would be useful and desirable to have a flexiblecarton assembly that can address multiple packaging requirements, and isalso cost effective.

SUMMARY OF THE INVENTION

The present invention overcomes the shortcomings of the known prior artby providing a carton assembly having an interior with inner wallsdefining a tray portion and an insert disposed within the tray portionthat is adapted for retaining an article within the interior of thecarton. In some embodiments the article is at least partially isolatedfrom contact with another article and/or the inner walls of the carton.Either the tray portion or the insert, or both include a structure forsupporting and securing the insert in place.

In one embodiment, a carton assembly comprises a carton having aplurality of foldable panels erected to define at least a pair ofopposing double wall structures. These double wall structures are spacedapart by an interior tray portion, and at least one of the double wallstructures includes a receiving structure for supporting an insert. Theinsert comprising at least one substantially hollow beam structureconfigured to at least partially retain at least one item. In addition,the insert is received by the tray portion and supported by thereceiving structure so as to receive and hold an article.

In another embodiment, the carton assembly the receiving structurecomprises at least one tab extending from at least one inner wall so asto be received by an open end of the hollow beam structure. Thereceiving structure further includes a center panel extending betweenthe tab and a bottom wall of the carton, the center panel being receivedin the open end of the hollow beam structure. In additional embodiments,the receiving structure further includes a protrusion extending from atleast one end of the hollow beam and a slot disposed in at least oneinner wall of the carton, the protrusion being received in the slot. Inthe various embodiments the insert partitions define recessed areasaccessible through an at least partially detachable end closure regionof the carton. In some embodiments a detachable end closure region isdefined at least in part by a frangible line.

One or more blanks are used to form a carton assembly. In a basicembodiment at least one panel is erectable into at least one set ofopposing, substantially-erect, spaced apart walls. Each wall has atleast one aperture disposed for alignment with an opposite wall apertureso as to form a passageway for receiving and retaining an article in theerected insert. In addition, the spaced apart walls form at least partof a beam structure in the erected insert; the beam structure caninclude at least one open end for attachment to an erected carton.Further, the substantially-erect, spaced apart walls cooperate withinterior walls of a carton to define an extended passageway. Embodimentsinclude the aperture, which is a cutout disposed to lie along an edge ofthe substantially-erect, spaced apart walls.

The present invention includes methods for forming a carton assembly.These non-limiting steps include: The step of erecting a carton blank toform a carton that includes at least a pair of opposing double wallstructures, and at least one of those double wall structures includes atleast one receiving structure. In addition is the step of erecting aninsert blank to form an insert having a hollow beam structure. Furtheris the step of inserting the insert into the carton such that the hollowbeam structure extends between the double wall structures. Further againis the step of supporting said insert with said receiving structure.

The foregoing has broadly outlined some of the aspects and features ofthe present invention, which should be construed to be merelyillustrative of various potential applications of the invention. Otherbeneficial results can be obtained by applying the disclosed informationin a different manner or by combining various aspects of the disclosedembodiments. Accordingly, other aspects and a more comprehensiveunderstanding of the invention may be obtained by referring to thedetailed description of the exemplary embodiments taken in conjunctionwith the accompanying drawings, in addition to the scope of theinvention defined by the claims.

BRIEF DESCRIPTION OF THE DRAWINGS

FIG. 1 is a plan view of an exemplary embodiment of a carton blank forforming a carton, according to the present invention.

FIG. 2 is a plan view of an exemplary embodiment of an insert blank forforming an insert, according to the present invention.

FIG. 3 is a perspective view of a carton assembly formed from the cartonblank of FIG. 1 and insert blank of FIG. 2.

FIG. 4 is a plan view of an exemplary embodiment of a carton blank forforming a carton, according to the present invention.

FIG. 5 is a plan view of an exemplary embodiment of a carton blank forforming a carton, according to the present invention.

FIG. 6 is a plan view of an exemplary embodiment of an insert blank forforming an insert, according to the present invention.

FIG. 7 is a plan view of an exemplary embodiment of a carton blank forforming a carton, according to the present invention.

FIG. 8 is a plan view of an exemplary embodiment of an insert blank forforming an insert, according to the present invention.

DETAILED DESCRIPTION

As required, detailed embodiments of the present invention are disclosedherein. It must be understood that the disclosed embodiments are merelyexemplary of the invention that may be embodied in various andalternative forms, and combinations thereof. As used herein, the word“exemplary” is used expansively to refer to embodiments that serve asillustrations, specimens, models, or patterns. The figures are notnecessarily to scale and some features may be exaggerated or minimizedto show details of particular components. In other instances, well-knowncomponents, systems, materials, or methods have not been described indetail in order to avoid obscuring the present invention. Therefore,specific structural and functional details disclosed herein are not tobe interpreted as limiting, but merely as a basis for the claims and asa representative basis for teaching one skilled in the art to variouslyemploy the present invention.

Referring now to the drawings, wherein like numerals indicate likeelements throughout the several views, the drawings illustrate certainof the various aspects of exemplary embodiments of a carton forpackaging elongated items, such as but not limited to vials andsyringes. Generally described, the carton includes an insert that isreceived in a tray portion of the carton to support articles within thecarton. The carton and the insert each include elements that cooperatewith one another to position and support the insert. The insert mayinclude slots for receiving, engaging, and/or supporting articles, ormay otherwise define compartments for receiving articles in the trayportion of the carton. The invention teaches several variations of ahollow-beam-structure type insert as well as tubular-structure types ofinserts. Each insert has opposing, substantially-erect, spaced apartwalls configured for alignment with at least one substantially-erect,spaced apart carton wall so as to form a passageway for receiving andretaining an article in the erected insert.

Referring to FIG. 1, a carton blank 100 is shown for forming a carton300, best shown in FIG. 3. The carton blank 100 includes primary panelsfor forming the outer walls of the carton 300 and inner structure panelsfor forming the inner walls of the carton 300. The inner walls define atray portion of the carton 300.

The primary panels of the carton blank 100 include a top panel 110, abottom panel 114, outer side panels 112, 116, and outer end panels 118,120. The panels 110, 112, 114, 116 are aligned longitudinally andhingedly connected one to the next along transverse fold lines. The endpanels 118, 120 are hingedly connected to opposing end edges of thebottom panel 114 along longitudinal fold lines. End flaps 122, 124 arehingedly connected to opposing end edges of the panels 110, 112, 116,respectively, along longitudinal fold lines. An edge flap 126 ishingedly connected to a side edge of the top panel 110 along atransverse fold line. For use herein, the terms longitudinal andtransverse refer to or reference elements relative to the longitudinalaxis of the blank. The transverse axis is substantially perpendicular tothe longitudinal axis.

The carton blank 100 further includes a series of inner structure panels132, 136 for forming the inner side walls of the carton 300, a series ofinner structure panels 138, 140 for forming each of the inner end wallsof the carton 300, and an inner bottom panel 134. In the exemplaryembodiment, each series of inner structure panels 132, 136 includes anupper edge side panel 150 and an inner side panel 152. The panels 132,134, 136 are hingedly connected one to the next along transverse foldlines and longitudinally align with the panels 110, 112, 114, 116.

Specifically, the inner side panels 152 are hingedly connected toopposite edges of the inner bottom panel 134 along fold lines 155 andthe upper edge side panels 150 are hingedly connected to the outermostedges of the inner side panels 152 along fold lines 153, respectively.The series of inner structure panels 132, 136 are hingedly connected tothe outer side panel 116 along a transverse fold line 151, and an innerside flap 156 is hingedly connected to the upper edge side panel 150along a transverse fold line 151. An aperture 154 is included in each ofthe inner structure panels 132, 136.

In an exemplary embodiment of an alternative carton blank, the innerstructure panels 132, 136 and the inner bottom panel 134 of the cartonblank 100 may be omitted such that a carton formed from the alternativecarton blank does not include these inner side walls. This may be done,for example, in instances where articles enclosed in the carton do notrequire the additional protection provided by more than one set ofdouble wall structures. Advantageously, less material is used to formthe alternative carton blank.

Continuing with reference to FIG. 1, each series of inner structurepanels 138, 140 includes an upper edge end panel 160, an inner end panel162, and an end bottom flap 164 that are hingedly connected one to thenext along longitudinal fold lines 163, 165. Each upper edge end panel160 is hingedly connected to a respective outer end panel 118, 120 alonga longitudinal fold line.

The carton blank 100 further includes features that form means forsupporting an insert when the carton blank 100 is erected to form thecarton 300. As described herein, means for supporting an insert includeselements of double wall structures and elements of inserts thatcooperate to support the insert in a tray portion to form a cartonassembly. In the illustrated embodiment, each of the upper edge endpanels 160 includes a tab 161 that is hingedly connected to a centerpanel 166 along a fold line 170. Each center panel 166 is created fromthe inner end panel 162 and the end bottom flap 164 by fold lines 170,172 and cut lines 168. The fold lines 170, 172 are outwardly offset,relative to the longitudinal center axis of the carton blank 100, fromthe fold lines 163, 165, respectively. Each tab 161 is created by thefold line 170 and the cut lines 168.

Referring now to FIG. 2, an insert blank 200 is shown for forming aninsert 400, best shown in FIG. 3. The insert blank 200 includes an upperedge center panel 210, center side panels 212, and bottom flaps 214 thathave substantially the same longitudinal length. Center side panels 212are hingedly connected to opposing side edges of the upper edge centerpanel 210 along longitudinal fold lines and center bottom flaps 214 arehingedly connected to the outermost side edges of the center side panels212 along longitudinal fold lines. The insert blank 200 further includesapertures 220.

In the exemplary embodiment, the apertures 220 have a size and shapethat facilitates supporting and/or securing elongated items, such asvials or syringes, when the insert 400 is erected, as described infurther detail below. The size, shape, number, and position of theapertures are design decisions that are based on the articles to besupported by the insert 400 or are otherwise based on ergonomics.

Referring to FIGS. 1 and 3, the illustrated carton blank 100 can befolded and erected to form the illustrated carton 300, as described inthe following non-limiting method. The outer side panels 112, 116 andthe outer end panels 118, 120 are folded to be substantiallyperpendicular to the bottom panel 114, thereby forming the outer side ofthe double walls of the tray portion of the carton 300. The end flaps124 are folded to be in a face contacting arrangement with, and securedto, respective outer end panels 118, 120. The panels 132, 134, 136 andinner side flap 156 are folded such that the inner side flap 156 is in aface contacting arrangement with the inside surface of the outer sidepanel 112 and such that the inner bottom panel 134 is in a facecontacting relationship with the inside surface of the outer bottompanel 114. Thereby, the upper edge side panels 150 are arranged to besubstantially parallel to the bottom panels 114, 134 and substantiallyperpendicular to the side panels 112, 116. The inner side panels 152 arearranged to be substantially perpendicular to the perimeter side panels150 and offset from, and substantially parallel to, the outer sidepanels 112, 116, respectively. In this manner, the inner side of thedouble walls 332, 336 are formed.

The inner structure panels 138, 140 are folded such that each end bottomflap 164 is in a face contacting relationship with the inside surface ofthe outer bottom panel 114. Thereby, the upper edge end panels 160 arearranged to be substantially parallel to both the outer bottom panel 114and the end bottom flaps 164, and are arranged to be substantiallyperpendicular to the outer end panels 118, 120, respectively. The innerend panels 162 are arranged to be substantially perpendicular to theupper edge end panels 160, and are arranged to be offset from, andsubstantially parallel to, the outer end panels 118, 120 to form adouble wall structure. The center panels 166 each extend between arespective tab 161 and end bottom flap 164. Each center panel 166 isinwardly offset from an inner end panel 162. In this manner, the innerside of the double walls 338, 340 are formed.

Generally described, the inner walls 332, 336, 338, 340 define a trayportion of the carton 300. Further, in the exemplary embodiment, meansfor supporting the insert 400 includes the tabs 161 and the center panel166, which are included in the inner end walls 338, 340. The carton 300receives and supports the insert 400, as described in further detailbelow. In alternative embodiments, the means for supporting are includedin the other inner walls 332, 336 and the insert 400 is positionedaccordingly.

Referring to FIGS. 2 and 3, the illustrated insert blank 200 can befolded to form the illustrated insert 400, as described in the followingnon-limiting method. The center side panels 212 and the center bottomflaps 214 are folded such that the center side panels 212 aresubstantially perpendicular to the upper edge center panel 210, and suchthat the center bottom flaps 214 are substantially perpendicular to thecenter side panels 212, respectively. Thereby, the insert 400 forms achannel or hollow beam structure with open ends O and the apertures 220define means for receiving articles. In the exemplary embodiment, theapertures 220 define slots 420. In alternative embodiments, means forreceiving articles include apertures, slots, recesses, cutouts, tabs,combinations thereof, and the like. The receiving elements are a designdecision that is based at least in part on the article to be received.

With reference now to FIG. 3, the insert 400 is received in the carton300 to form a carton assembly 500. Specifically, the center bottom flaps214 of the insert 400 are in a face contacting arrangement with theinner bottom panel 134 and the end bottom flaps 164. The insert 400 isat least partially retained in a folded or erected form as the edges ofthe center bottom flaps 214 abut against the inner side walls 332, 336such that the center bottom flaps 214 are restricted from moving awayfrom one another. The center side panels 212 and upper edge center panel210 are maintained in an erected position by means for supporting theinsert 400. In the exemplary embodiment, means for supporting the insert400 includes the tabs 161, the center panels 166, and the open ends O ofthe insert 400. The open ends O of the insert 400 receive the tab 161and center panel 166 as the insert 400 is received by the carton 300,such that the upper surface of the tab 161 is in contact with the insidesurface of the upper edge center panel 210. The edges of the tab 161 andcenter panel 166, which are defined by cut lines 168, contact the insidesurfaces of the center side panels 212 such that the center side panels212 and upper edge center panel 210 are retained in an erected position.Specifically, the channel or hollow beam structure of the insert 400does not collapse or deflect in response to a side or lateral force thatis provided as articles are received or removed from the slots 420. Insum, the tabs 161 and center panel 166 receive and support the insert400 such that a portion of the insert 400 forms a central wall orpartition that extends between the inner end walls 332, 336.

It should be understood that means for supporting the insert is notlimited to the elements described in the exemplary embodiment. Rather,means for supporting the insert includes additional elements, asdescribed below. The exemplary embodiments described below shareelements with the exemplary embodiment described above. Therefore, forsimplicity, only certain elements will be described in detail for theexemplary embodiments. For example, the primary panels of the cartonblanks described below share elements with the primary panels of thecarton blank 100, and therefore will not be described in detail.

Referring to FIG. 4, an exemplary embodiment of a carton blank 800includes elements that form means for supporting an insert when a cartonis formed from the carton blank 800. The carton blank 800 includes aseries of inner structure panels 838, 840 that each include an upperedge end panel 860, an inner end panel 862, and a bottom flap 864 thatare hingedly connected along longitudinal fold lines 863, 865. The upperedge end panel 860 is hingedly connected to a respective outer sidepanel 818, 820 along a longitudinal fold line. In this embodiment, eachof the upper edge end panels 860 includes a tab 861 that is defined bycut lines 868, 870. The cut line 870 is offset from the fold line 863.When the carton blank 800 is folded and erected to form a carton, meansfor supporting an insert includes the tab 861. Specifically, the openends of an insert receive the tab 861, as described above. The uppersurface of the tab 861 is in flat face contact with the inside surfaceof the insert's upper edge center panel 210 and the edges of the tab861, which are defined by cut lines 868, engage the inside surfaces ofthe center side panels of an insert such that the center side panels andupper edge center panel of the insert are supported in an erectedposition.

It should be noted that the shape of the tab 861 is not limited to therectangular shape shown in FIG. 4. Rather, the tab 861 may be any shapethat facilitates retaining an insert in an erected position. Forexample, the cut line 870 may be curved or otherwise nonlinear to definea dome-shaped tab 861. Further, as described below, means for supportingmay be used to additionally secure the tab 861 to the upper edge centerpanel 210 of an insert.

In various exemplary embodiments, the carton assembly may include meansfor supporting an insert with multiple hollow beam structures orotherwise multiple inserts with a hollow beam structure. In an exemplaryembodiment, not shown, a carton assembly according to the presentinvention is formed of an insert that includes two hollow beamstructures and a carton that includes means for supporting each hollowbeam structure. Specifically, and with continued reference to FIG. 4,the carton blank 800 includes two tabs 861 defined in each series oftray panels 838, 840. The tabs 861 of the carton are received in theopen ends of respective hollow beam structures of the insert to providemeans for supporting the insert, as described above. In this embodiment,the insert partitions the tray portion of the carton such that thecarton assembly includes three recessed areas for receiving articles.The slots in the hollow beam structures defined by apertures (220 shownin FIG. 2), and the slots in the inner side walls defined by apertures854, facilitate accessing an article or articles disposed in eachrecessed area.

In another exemplary embodiment, a carton formed from a carton blank andan insert formed form an insert blank include elements which cooperateto releasably lock the insert in the tray portion of the carton. As bestdescribed with reference to FIG. 4, the blank 800 includes cutouts C inthe inner side panels 852 such that the outermost portion of the bottomedge of the inner side panel 852 is offset from the fold line 855, whichhingedly connects each inner side panel 852 to the inner bottom panel834. Thereby, as the carton blank 800 is folded and secured to form acarton, as described above, the cutouts C define openings in the innerside walls that are adjacent to the bottom wall of the carton. An insertblank (not shown) includes locking tabs along the side edges of thebottom flaps (214, best shown in FIG. 2), which correspond to thecutouts in the inner side walls of the carton. As the insert formed fromthe blank is received in the tray portion of the carton, the tabs arereceived in the cutouts to releasably lock the insert in the trayportion of the carton and thereby form a carton assembly.

In another exemplary embodiment (not shown), a carton assembly includesa carton formed from a carton blank and an insert formed from an insertblank. The carton blank includes inner structure panels (838, 840 shownin FIG. 4) for forming the inner end walls of the carton. The innerstructure panels include an aperture (861 shown in FIG. 4). In thisembodiment, the aperture is disposed in the upper edge end panel and theinner end panel such that the aperture interrupts the fold line (863shown in FIG. 4) but no other fold line. In this exemplary embodiment,the aperture is substantially rectangular and the width of the apertureis substantially the same, but slightly greater than, the width of theupper edge center panel (210 shown in FIG. 2) of the insert blank.

Here, tabs protrude from opposite end edges of the insert blank and aresubstantially aligned with the upper edge center panel. The tabs arewider than the center perimeter panel such that the tabs extend from thecenter perimeter panel and the side panels.

Here also, a carton is formed from the carton blank such that theapertures form slots in the inner end walls. An insert is erected fromthe insert blank to form a channel or hollow beam structure such thatthe tabs form hollow beam protrusions. The hollow beam protrusionsextend from the open ends of the insert. The carton assembly is formedas the hollow beam protrusions are received in the slots. The slotsreceive and engage the hollow beam protrusions to provide means forsupporting the insert. In this embodiment, the edges of the tabs areoffset from the longitudinal fold lines that connect the center sidepanel to the center bottom flaps, by a distance D2. Similarly, thenearest edge of the aperture is offset from the fold line by a distanceD1. The distance D2 is no greater than the distance D1 such that thehollow beam protrusions are received in the slots, which are offset fromthe bottom wall of the carton.

A related alternative carton assembly includes a carton formed from acarton blank and an insert formed from an insert blank that includesmultiple hollow beam structures. Means for supporting the insertincludes multiple slots and multiple hollow beam protrusions, similar tothose described immediately above. Accordingly, the carton blankincludes two apertures in each series of inner structure panels and theinsert blank includes tabs that extend from, and are aligned with, eachupper edge center panel.

Referring to yet another alternative embodiment of a carton (not shown),the inner structure panels (138, 140 shown in FIG. 1) include apertures(161 shown in FIG. 1). The apertures are defined by a fold line (165shown in FIG. 1), extend the length of the inner end panel (162 shown inFIG. 1), interrupt the fold line (163 shown in FIG. 1), and define arecess in the upper edge end panel (160 shown in FIG. 1). The insertincludes hollow beam protrusions that have a height that issubstantially the same as the center side panels (212 shown in FIG. 2).The apertures form slots in the carton formed from the blank to receivethe hollow beam protrusions to support the insert.

Referring to FIGS. 5 and 6, components for an alternative cartonassembly is shown. The carton assembly includes a carton formed from anexemplary embodiment of a carton blank 2500 and an insert formed from anexemplary embodiment of an insert blank 2600. In this embodiment, theinner structure panels 2532, 2536 include apertures 2561 that extendfrom the fold line 2551, across the upper edge side panel 2550, and ontothe inner side panel 2552 such that the apertures 2561 define a recessin the inner side panel 2552 and interrupt the fold line 2553. Theapertures 2561 are offset from the fold line 2555 by a distance D1 suchthat the apertures 2561 define slots in the inner side walls of theerected carton. The slots 2761 are thereby offset from the bottom wallof the carton by a distance D2. Tabs 2622 extend from the edges of theinsert blank 2600 to form hollow beam protrusions. The hollow beamprotrusions are received in the slots such that the hollow beamstructures of the insert extend between the inner side walls of thecarton. It should be noted that, in another exemplary embodiment of acarton blank, the inner structure panels 2538, 2540 of the carton blank2500 may be omitted such that a carton formed from the carton blankincludes only one pair of spaced apart double wall structures.

In yet another exemplary embodiment, a carton assembly includes an atleast partially detachable end closure region. The detachable end isdefined by an at least partially frangible line 2908, which extendsacross the primary panels of a carton blank 2900, best shown in FIG. 7.In this embodiment, an insert partitions the sleeve portion of a cartonsuch that the carton assembly includes two recessed areas for receivingarticles. Articles can be loaded into the recessed areas of the trayportion of a carton assembly in a similar fashion as for certain of theexemplary embodiments described above. Specifically, articles can be toploaded into the tray portion of the carton assembly before securing thetop panel 2910 to enclose the articles in the carton assembly. However,in this embodiment, articles are accessed by at least partiallydetaching the detachable end along the frangible line 2908.

One advantage of the embodiments of carton assemblies described above isthat the inner walls of the cartons provide protection in addition tostabilizing or anchoring the inserts. For example, the inner walls ofthe carton space the inserts from the outer walls of the carton in orderto prevent articles in the carton assembly from breakage during shippingand handling. Alternative embodiments, wherein the carton assembly isnot or square or rectangular as shown, but is configured as a triangleor a polygon, are likewise contemplated. Such alternative shapes mayincrease the advantages of the present invention.

In another exemplary embodiment, a carton assembly includes an insertformed from an insert blank 3100, best shown in FIG. 8. The insert blank3100 includes a plurality of panels aligned in a longitudinal directionand hingedly connected along transverse fold lines. In the exemplaryembodiment, the insert blank 3100 includes end panels 3110 and sidepanels 3112. The insert blank 3100 further includes bottom flaps 3114and an optional glue flap G. A longitudinal edge E of each of the sidepanels 3112 includes cutouts 3120. Specifically, each side panel 3112includes a pattern P1, P2 of cutouts 3120. The insert is erected as theoutside of the glue flap G is secured to the inside surface of theoutermost end panel 3110 such that the end and side panels 3110, 3112form a tubular structure and such that the pattern P1 of cutouts 3120aligns with the pattern P2 of cutouts 3120 to define a slot forreceiving an article. It is understood that the patterns P1, P2 are notlimited to those shown herein, but may include many various alternativesconsistent with the present invention. Additionally, the bottom flaps3114 are folded outwardly such that they are substantially coplanar withone another. The insert is received in a carton to form the cartonassembly. In the exemplary embodiment, the bottom flaps 3114 are securedto the bottom wall of the carton.

Each of the blanks described herein includes a single sheet of suitablesubstrate. Alternative embodiments include multiple sheets of substrate,while some embodiments are made of components of the illustrated blanks.It is to be understood that, as used herein the term “suitablesubstrate” includes all manner of foldable sheet material such aspaperboard, corrugated board, plastic, or the like. The terms “foldline” and “severance line” refer to all manner of printed linesindicating optimal fold or cut locations, frangible or otherwiseweakened lines, perforations, a line of perforations, a line of shortslits, a line of half-cuts, a single half-cut, a cut line, scored lines,slits, any combination thereof, and the like.

It should be noted that erecting the cartons and inserts from respectiveblanks may be accomplished with the folding operations as describedherein, where the operations are performed by automatic erectingmachinery and/or manually. The method of performing the erecting processis not limited to the exemplary method described herein, particularly inthat the order of the steps can be altered according to the particularmanufacturing requirements, steps may be added or omitted, and the meansfor supporting components may vary.

The surfaces of sheet material may be secured together by suitable meansfor securing, such suitable securing means including tape, staples,interlocking folds, loop and hook fasteners, glue or other adhesives,and the like. Specifically, the sheet material of a carton blank may besecured together by suitable means to form a carton. Similarly, thesheet material of an insert may be secured to the sheet material of acarton to form a carton assembly.

The law does not require and it is economically prohibitive toillustrate and teach every possible embodiment of the present claims.Hence, the above-described embodiments are merely exemplaryillustrations of implementations set forth for a clear understanding ofthe principles of the invention. Variations, modifications, andcombinations may be made to the above-described embodiments withoutdeparting from the scope of the claims. All such variations,modifications, and combinations are included herein by the scope of thisdisclosure and the following claims.

1. A carton assembly, comprising: a carton having a plurality offoldable panels erected to define at least a pair of opposing doublewall structures spaced apart by an interior tray portion, wherein atleast one of said double wall structures includes a receiving structurefor supporting an insert; an insert comprising at least onesubstantially hollow beam structure configured to at least partiallyretain at least one item; and, wherein said insert is received by saidtray portion and supported by said receiving structure.
 2. The cartonassembly of claim 1, wherein said receiving structure comprises at leastone tab extending from at least one double wall structure so as to bereceived by an open end of said hollow beam structure.
 3. The cartonassembly of claim 2, wherein said receiving structure further includes acenter panel extending between said tab and a bottom wall of saidcarton, said center panel being received in said open end of said hollowbeam structure.
 4. The carton assembly of claim 2, wherein saidreceiving structure further includes a protrusion extending from atleast one end of said hollow beam and a slot disposed in at least oneinner wall of said carton, said protrusion being received in said slot.5. The carton assembly of claim 1, wherein said insert partitions saidtray portion of said carton to define recessed areas.
 6. The cartonassembly of claim 5, wherein said recessed areas are accessible throughan at least partially detachable end closure region of said carton. 7.The carton assembly of claim 6, wherein said detachable end closureregion is defined at least in part by a frangible line.
 8. A blank forforming a carton assembly insert, comprising: at least one panelerectable into at least one set of opposing, substantially-erect, spacedapart walls, each wall having at least one aperture disposed foralignment with an opposite wall aperture so as to form a passageway forreceiving and retaining an article in the erected insert.
 9. The blankof claim 8, wherein said substantially-erect, spaced apart walls form atleast part of a beam structure in the erected insert.
 10. The blank ofclaim 8, wherein said substantially-erect, spaced apart walls cooperatewith interior walls of a carton to define an extended passageway. 11.The blank of claim 9, wherein said beam structure has at least one openend in the erected insert.
 12. The blank of claim 8, wherein said atleast one aperture is a cutout disposed to lie along an edge of saidsubstantially-erect, spaced apart walls in the erected insert.
 13. Amethod for forming a carton assembly, comprising: erecting a cartonblank to form a carton, including at least a pair of opposing doublewall structures having at least one receiving structure; erecting aninsert blank to form an insert, the insert having a hollow beamstructure; inserting said insert into said carton such that said hollowbeam structure extends between said double wall structures; andsupporting said insert with said receiving structure.